Systems and methods for inspecting bristles using a digital camera

Abstract

A method is provided for inspecting a device comprising a plurality of bristles. During this method, image data provided from an electronic optical sensor is received. The image data is indicative of an image of at least a portion of the bristles. A bristle configuration (e.g., an angle) of at least one of the bristles (e.g., an average bristle) in the image is determined by processing the image data with a computer processor.

What is claimed is: 
     
       1. A method for inspecting a device comprising a plurality of bristles, the method comprising:
 arranging the device with a fixture to locate the device in a known spatial location and orientation; 
 receiving image data provided from an electronic optical sensor, the image data indicative of an image of at least a portion of the bristles; and 
 determining a bristle configuration of at least one of the bristles in the image by processing the image data with a computer processor, wherein the bristle configuration is determined based on the known spatial location and orientation, and the determining of the bristle configuration comprises determining an angle between the at least one of the bristles and a reference line; 
 wherein the device further comprises an annular base that extends circumferentially around a centerline, and the plurality of bristles are connected to and project from the annular base. 
 
     
     
       2. The method of  claim 1 , wherein the reference line is coincident with and perpendicular to the centerline. 
     
     
       3. The method of  claim 1 , wherein the plurality of bristles project radially inward from a radial inner periphery of the annular base. 
     
     
       4. The method of  claim 1 , wherein the plurality of bristles project radially outward from a radial outer periphery of the annular base. 
     
     
       5. The method of  claim 1 , wherein the plurality of bristles project axially away from an axial side of the annular base. 
     
     
       6. The method of  claim 1 , wherein the electronic optical sensor is fixedly mounted to the fixture. 
     
     
       7. The method of  claim 1 , wherein the electronic optical sensor is mounted to the fixture, and the electronic optical sensor is adapted to move relative to the device. 
     
     
       8. The method of  claim 7 , further comprising adjusting the location of the electronic optical sensor based on a configuration of the device. 
     
     
       9. The method of  claim 1 , wherein the fixture comprises a first seal locator and a second seal locator, and the device is abutted against the first seal locator and the second seal locator. 
     
     
       10. The method of  claim 9 , further comprising adjusting a location of the first seal locator and/or a location of the second seal locator based on a configuration of the device. 
     
     
       11. The method of  claim 1 , wherein the bristle configuration is determined using an autocorrelation function. 
     
     
       12. The method of  claim 1 , wherein the bristle configuration further comprises a dimension of the at least one of the bristles. 
     
     
       13. The method of  claim 1 , wherein the device is configured as a brush seal for a gas turbine engine. 
     
     
       14. A method for inspecting a device comprising a plurality of bristles, the method comprising:
 receiving image data provided from an electronic optical sensor, the image data indicative of an image of at least a portion of the bristles; and 
 determining a bristle configuration of at least one of the bristles in the image by processing the image data with a computer processor, wherein the determining of the bristle configuration comprises determining an angle between the at least one of the bristles and a reference line, and the determining of the bristle configuration further comprises:
 calculating an autocorrelation function on an array of pixels of the image; 
 determining a peak intensity of the autocorrelation function along each row or each column of the array of pixels; 
 fitting a least square error line based on the peak intensity; and 
 determining the angle based on a slope of the least square error line; 
 
 wherein the device further comprises an annular base that extends circumferentially around a centerline, and the plurality of bristles are connected to and project from the annular base. 
 
     
     
       15. The method of  claim 14 , wherein the plurality of bristles project one of
 radially inward from a radial inner periphery of the annular base; and 
 radially outward from a radial outer periphery of the annular base. 
 
     
     
       16. The method of  claim 14 , wherein the plurality of bristles project axially away from an axial side of the annular base. 
     
     
       17. A method for inspecting a device comprising a plurality of bristles, the method comprising:
 receiving image data provided from an electronic optical sensor, the image data indicative of an image of at least a portion of the bristles; and 
 determining a bristle configuration of at least one of the bristles in the image by processing the image data with a computer processor, wherein the determining of the bristle configuration comprises determining an angle between the at least one of the bristles and a reference line, and the determining of the bristle configuration further comprises:
 determining a first number of the plurality of bristles located along an x-axis in a quadrant of the image; 
 determining a second number of the plurality of bristles located along a y-axis in the quadrant of the image; and 
 calculating an arctangent of R to determine the angle, wherein R is equal to a quotient of the second number divided by the first number; 
 
 wherein the device further comprises an annular base that extends circumferentially around a centerline, and the plurality of bristles are connected to and project from the annular base. 
 
     
     
       18. The method of  claim 17 , wherein the plurality of bristles project one of
 radially inward from a radial inner periphery of the annular base; and 
 radially outward from a radial outer periphery of the annular base. 
 
     
     
       19. The method of  claim 17 , wherein the plurality of bristles project axially away from an axial side of the annular base. 
     
     
       20. The method of  claim 17 , wherein the device is configured as a brush seal for a gas turbine engine.